Building materials comprising carbon-dioxide-treated agglomerated particles

ABSTRACT

Roofing granules comprising agglomerated inorganic material treated with carbon dioxide gas, and building materials, such as shingles, that include such roofing granules. By fabricating roofing granules from agglomerating inorganic material it is possible to tailor the particle size distribution so as to provide optimal shingle surface coverage, thus reducing shingle weight and usage of raw materials. Additionally, the use of agglomeration permits the utilization of by-products from conventional granule production processes.

FIELD OF THE INVENTION

The invention relates to building materials (such as shingles) that include roofing granules comprising agglomerated inorganic material. The invention also relates to roofing granules comprising agglomerated inorganic material. By fabricating roofing granules from agglomerated inorganic material, it is possible to tailor the particle size distribution so as to provide improved surface coverage for roofing products, thus reducing roofing product weight and usage of raw materials. Additionally, the use of agglomeration permits the utilization of by-products from conventional granule production processes. In some embodiments, the agglomerated inorganic material is treated by being exposed to carbon dioxide gas. Such treatment may reduce its solubility.

BACKGROUND OF THE INVENTION

Roofing products are an important category of building material. Roofing products are often divided into three broad groups: shingles, roll roofing, and underlayment. Roofing shingles have been used extensively in residential housing as roof covering due to their aesthetics, ease of installation, water shedding function, and excellent field performance over a long period of time.

Traditional roofing shingles are based upon a fiberglass or felt mat that is coated and impregnated with an asphalt-based composition that is coated with roofing granules. Roofing shingles may be single layer strip shingles, laminated shingles having two or more layers, interlocking shingles and large individual shingles in a variety of weights and colors. Such laminated asphalt shingles are also often referred to as composite shingles, architectural shingles or dimensional shingles.

The shingle fiberglass or felt mat serves as a matrix to support the other components and gives the shingle the required strength to withstand manufacturing, handling, installation and service in the intended environment. An asphalt coating formulated for the particular service application is often applied to the base material to provide the desired long-term ability to resist weathering and to provide stability under temperature extremes.

Typically, the roofing granules applied to roofing shingles or roll roofing are size-graded stone particles. Different sizes of roofing granules may be applied to different areas of the shingle surface (e.g., back surface, headlap, buttlap, etc.) depending on the required properties of a given area. For example, roofing granules may protect the shingle asphalt from UV and impact damage, provide aesthetic effects on exposed surfaces and impart fire resistance.

It is beneficial to minimize the weight of roofing granules applied to the shingle or roll roofing in order to reduce (a) roof loading; (b) shipping costs; (c) raw material utilization; and (d) to facilitate installation. It is also advantageous to reduce raw material costs by making use of by-products of other processes, such as rock fines.

There is thus a need for roofing granules that provide optimal shingle or roll roofing surface covering and that can be made from waste materials, such as rock fines.

SUMMARY OF THE INVENTION

In one aspect, one embodiment relates to a method comprising: (1) obtaining (a) a plurality of fragments of at least one of a rock, a mineral, or a combination thereof and (b) a binder; (2) mixing (a) the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof and (b) the binder to produce an agglomerated particle that is formed by agglomerating together the plurality of fragments and the binder; (3) drying the agglomerated particle; and (4) treating the agglomerated particle with carbon dioxide gas.

In one embodiment, the treating the agglomerated particle with carbon dioxide gas comprises placing the agglomerated particle in a chamber having a greater than atmospheric level of carbon dioxide gas.

In one embodiment, the greater than atmospheric level of carbon dioxide gas is from 25% to 100% by volume based on a total volume of the chamber.

In one embodiment, the carbon dioxide gas comprises gas from a combustion process.

In one embodiment, the treating takes place after the drying.

In one embodiment, the treating the agglomerated particle with carbon dioxide gas comprises placing the agglomerated particle in a chamber having a greater than atmospheric level of carbon dioxide gas, wherein the greater than atmospheric level of carbon dioxide gas is from 25% to 100% by volume based on a total volume of the chamber, and wherein the treating the agglomerated particle with carbon dioxide gas extends for a time period of from 10 minutes to 120 minutes.

In one embodiment, the greater than atmospheric level of carbon dioxide gas is from 70% to 100% by volume based on a total volume of the chamber.

In one embodiment, the treating the agglomerated particle with carbon dioxide gas extends for a time period of from 30 minutes to 120 minutes.

In one embodiment, the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size passing US Mesh 40.

In one embodiment, the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size passing US Mesh 100 but retained by US Mesh 270, wherein the agglomerated particle is not sintered, wherein the agglomerated particle is configured to be applied to a sheet to form a roofing product, wherein the roofing product is a shingle or roll roofing, wherein the agglomerated particle is substantially spherical, wherein the at least one of a rock, a mineral, or a combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite, or a combination thereof, and wherein the binder is present in in the agglomerated particle in an amount of 1 wt % to 10 wt % with respect to a total weight of the agglomerated particle.

In one embodiment, the binder is present in the agglomerated particle in an amount of 2 wt % to 8 wt %.

In one embodiment, the binder is present in the agglomerated particle in an amount of 2 wt % to 6 wt %.

In one embodiment, the binder comprises at least one of sodium silicate, gypsum, or a combination thereof.

In one embodiment, the binder comprises sodium silicate.

In one embodiment, the aforementioned method further comprises coating the treated agglomerated particle with a coating comprising silicate and clay.

In one embodiment, the aforementioned method further comprises: coating a sheet comprising a fiberglass mat with asphalt; and applying the treated agglomerated particle to the coated sheet.

In one embodiment, the mixing comprises using a pin mixer, and the aforementioned method further comprises pelletizing the agglomerated particle before the drying.

In one embodiment, the drying achieves a moisture content in the agglomerated particle of 0.4-5 wt % based on the total weight of the agglomerated particle.

In one embodiment, the drying achieves a moisture content in the agglomerated particle of 1 to 3 wt % based on the total weight of the agglomerated particle.

Another embodiment relates to an agglomerated particle comprising: (a) a plurality of fragments of at least one of a rock, a mineral, or a combination thereof and (b) a binder, wherein the agglomerated particle is a carbon-dioxide-gas-treated agglomerated particle.

In one embodiment of the agglomerated particle, the carbon dioxide gas treatment comprises exposing the agglomerated particle to carbon dioxide gas other than atmospheric carbon dioxide gas.

In one embodiment of the agglomerated particle, the carbon dioxide gas treatment comprises exposing the agglomerated particle to an environment in which a level of carbon dioxide gas is from 25% to 100% by volume, wherein the agglomerated particle is configured to be applied to a sheet to form a roofing product, wherein the roofing product is a shingle or roll roofing, wherein the at least one of a rock, a mineral, or a combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite, or a combination thereof, wherein the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size passing US Mesh 40, wherein the agglomerated particle is substantially spherical, wherein the binder is present in the agglomerated particle in an amount of 2 wt % to 8 wt %, and wherein the binder is at least one of sodium silicate, gypsum, or a combination thereof.

Another embodiment relates to a roofing product comprising: a sheet to which is applied a plurality of particles, each being an agglomerated particle as mentioned above.

In one embodiment of the aforementioned roofing product, the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size passing US Mesh 100 but retained by US Mesh 270, and wherein, when wt % is assessed with respect to a total weight of the plurality of particles, (A) the plurality of particles have a particle size distribution comprising (1) at least about 10 wt % retained by US Mesh 50 after passing US Mesh 40, (2) at least about 5 wt % retained by US Mesh 60 after passing US Mesh 50, and (3) at least about 5 wt % retained by US Mesh 100 after passing US Mesh 70; or (B) the plurality of particles have a particle size distribution comprising (1) at least about 40 wt % retained by US Mesh 16 after passing US Mesh 12, (2) at least about 30 wt % retained by US Mesh 20 after passing US Mesh 16, and (3) at least about 20 wt % retained by US Mesh 30 after passing US Mesh 20; or (C) the plurality of particles have a particle size distribution comprising (1) at least about 1 wt % retained by US Mesh 20 after passing US Mesh 16, (2) at least about 40 wt % retained by US Mesh 30 after passing US Mesh 20, and (3) at least about 2 wt % retained by US Mesh 40 after passing US Mesh 30.

Yet another embodiment relates to a method comprising: obtaining (a) at least one of a rock, a mineral, or a combination thereof and (b) a binder; mixing (a) the at least one of a rock, a mineral, or a combination thereof and (b) the binder to produce agglomerated particles; and applying the agglomerated particles to a sheet to form a roofing product.

Another embodiment relates to a method comprising: (1) obtaining (a) at least one of a rock, a mineral, or a combination thereof and (b) a binder, wherein the at least one of a rock, a mineral, or a combination thereof have a particle size passing US Mesh 40; (2) mixing (a) the at least one of a rock, a mineral, or a combination thereof and (b) the binder to produce unsintered agglomerated particles; and (3) applying the unsintered agglomerated particles to a sheet to form a roofing product.

In another aspect, the roofing product is a shingle or roll roofing.

In another aspect, the binder is present in in the agglomerated particles in an amount of 1 wt % to 10 wt % with respect to a total weight of the agglomerated particles.

In yet another aspect, the binder is present in in the agglomerated particles in an amount of about 2 wt % to 10 wt %.

In another aspect, the binder is present in in the agglomerated particles in an amount of about 6 wt % to 10 wt %.

In another aspect, the at least one of a rock, a mineral, or a combination thereof comprises one or more of basalt, metabasalt, andesite, and rhyolite.

In another aspect, the binder is at least one of sodium silicate, gypsum, or a combination thereof.

In another aspect, the at least one of a rock, a mineral, or a combination thereof comprises metabasalt.

In another aspect, the binder comprises sodium silicate.

In another aspect, the agglomerated particles have a coating comprising silicate and clay.

In another aspect, the mixing uses a pin mixer.

In another aspect, the method further comprises pelletizing the agglomerated particles.

In another aspect, the method further comprises drying the agglomerated particles.

Yet another embodiment relates to a method comprising: (1) obtaining (a) at least one of a rock, a mineral, or combination thereof and (b) a binder; (2) mixing the at least one of a rock, a mineral, or a combination thereof and the binder to produce agglomerated particles; and (3) applying the agglomerated particles to a sheet to form a shingle, wherein, when wt % is assessed with respect to a total weight of the agglomerated particles, (A) the agglomerated particles have a particle size distribution comprising (1) at least about 10 wt % retained by US Mesh 50 after passing US Mesh 40, (2) at least about 5 wt % retained by US Mesh 60 after passing US Mesh 50, and (3) at least about 5 wt % retained by US Mesh 100 after passing US Mesh 70; or (B) the agglomerated particles have a particle size distribution comprising (1) at least about 40 wt % retained by US Mesh 16 after passing US Mesh 12, (2) at least about 30 wt % retained by US Mesh 20 after passing US Mesh 16, and (3) at least about 20 wt % retained by US Mesh 30 after passing US Mesh 20; or (C) the agglomerated particles have a particle size distribution comprising (1) at least about 1 wt % retained by US Mesh 20 after passing US Mesh 16, (2) at least about 40 wt % retained by US Mesh 30 after passing US Mesh 20, and (3) at least about 2 wt % retained by US Mesh 40 after passing US Mesh 30.

In another aspect, the agglomerated particles have a particle size distribution comprising (1) at least about 20 wt % retained by US Mesh 50 after passing US Mesh 40, (2) at least about 10 wt % retained by US Mesh 60 after passing US Mesh 50, and (3) at least about 10 wt % retained by US Mesh 100 after passing US Mesh 70.

In another aspect, the agglomerated particles have a particle size distribution comprising (1) at least about 30 wt % retained by US Mesh 50 after passing US Mesh 40, (2) at least about 20 wt % retained by US Mesh 60 after passing US Mesh 50, and (3) at least about 20 wt % retained by US Mesh 100 after passing US Mesh 70.

In another aspect, the agglomerated particles have a particle size distribution comprising (1) at least about 40 wt % retained by US Mesh 16 after passing US Mesh 12, (2) at least about 30 wt % retained by US Mesh 20 after passing US Mesh 16, and (3) at least about 20 wt % retained by US Mesh 30 after passing US Mesh 20.

In another aspect, the agglomerated particles have a particle size distribution comprising (1) at least about 2 wt % retained by US Mesh 20 after passing US Mesh 16, (2) at least about 50 wt % retained by US Mesh 30 after passing US Mesh 20, and (3) at least about 10 wt % retained by US Mesh 40 after passing US Mesh 30.

In another aspect, the agglomerated particles have a particle size distribution comprising (1) at least about 5 wt % retained by US Mesh 20 after passing US Mesh 16, (2) at least about 60 wt % retained by US Mesh 30 after passing US Mesh 20, and (3) at least about 20 wt % retained by US Mesh 40 after passing US Mesh 30.

In another aspect, the binder is present in in the agglomerated particles in an amount of 1 wt % to 10 wt % with respect to a total weight of the agglomerated particles.

In another aspect, the binder is present in in the agglomerated particles in an amount of about 6 wt % to 10 wt %.

In a still further aspect, the binder is at least one of sodium silicate, gypsum, or a combination thereof

In another aspect, the agglomerated particles have a coating comprising silicate and clay.

In another aspect, the mixing uses a pin mixer.

In another aspect, the method further comprises pelletizing the agglomerated particles.

In another aspect, the method further comprises drying the agglomerated particles.

Yet another embodiment relates to a shingle or roll roofing comprising agglomerated particles comprising (a) at least one of a rock, a mineral, or a combination thereof and (b) a binder, wherein, when wt % is assessed with respect to a total weight of the agglomerated particles, (A) the agglomerated particles have a particle size distribution comprising (1) at least about 10 wt % retained by US Mesh 50 after passing US Mesh 40, (2) at least about 5 wt % retained by US Mesh 60 after passing US Mesh 50, and (3) at least about 5 wt % retained by US Mesh 100 after passing US Mesh 70; or (B) the agglomerated particles have a particle size distribution comprising (1) at least about 40 wt % retained by US Mesh 16 after passing US Mesh 12, (2) at least about 30 wt % retained by US Mesh 20 after passing US Mesh 16, and (3) at least about 20 wt % retained by US Mesh 30 after passing US Mesh 20; or (C) the agglomerated particles have a particle size distribution comprising (1) at least about 1 wt % retained by US Mesh 20 after passing US Mesh 16, (2) at least about 40 wt % retained by US Mesh 30 after passing US Mesh 20, and (3) at least about 2 wt % retained by US Mesh 40 after passing US Mesh 30.

Among those benefits and improvements that have been disclosed, other objects and advantages of this invention will become apparent from the following description. Detailed embodiments of the invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention which are intended to be illustrative, and not restrictive.

Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases “in one embodiment” and “in some embodiments” as used herein do not necessarily refer to the same embodiment(s), though they may. Furthermore, the phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although they may. Thus, as described below, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention.

DETAILED DESCRIPTION

One embodiment pertains to a roofing shingle that includes roofing granules comprised of agglomerated particles. Agglomerated particles may be applied to the back surface, buttlap and/or headlap of the shingle. In an embodiment, the agglomerated particles applied to the back surface, buttlap and/or headlap of the shingle have different particle size distributions. The choice of particle size distribution selected for a shingle surface may be influenced by the balance of surface coverage, shingle weight, degree of flatness and impact resistance required. The shingle may be a single-layer shingle or a laminated shingle.

Examples of a sheet that may be used to make the shingle are as follows. In particular, in an embodiment, the shingle may be formed from a fiberglass mat with an asphalt coating on both sides of the mat. In an embodiment, the shingle may be formed from organic felt or other types of base material, including synthetic mats or synthetic glass/hybrid mats having an appropriate coating. Non-limiting examples of coatings include asphalt and modified bituminous coatings based on atactic polypropylene (APP), styrene-butadiane-styrene (SBS), styrene-ethylene-butadiene-styrene (SEBS), amorphous polyalpha olefin (APAO), thermoplastic polyolefin (TPO), synthetic rubber or other asphaltic modifiers.

In an embodiment, two or more shingles are installed on a roof deck in a roofing system such that the shingles are in a row from left to right and the lateral edges of the shingles in the row are contiguous with each other so as to abut each other, i.e., their lateral edges are adjacent to one another. Each row represents a course and the shingles are applied in overlapping courses on the roof deck, wherein the buttlap portion of a subsequent course is placed on the headlap portion of a previous course. In an embodiment, the headlap portion of the shingle is at least as wide as the buttlap portion of the shingle so that when the shingles are installed on a roof deck in overlapping courses, the entire buttlap portion of a subsequent course has headlap beneath it. In an embodiment, an edge of the shingle has a plurality of dragon teeth with openings therebetween. In an embodiment of the laminated shingle, a backer strip is provided under the dragon teeth, with portions of the backer strip exposed through the openings between the dragon teeth. In an embodiment of the single layer shingle, when the shingle is installed on a roof deck, the dragon teeth of a second layer of shingles is placed on the headlap of a previously installed layer of shingles, such that portions of the headlap region are exposed through the openings between the dragon teeth.

One embodiment pertains to a roofing system comprising one or more shingles that comprise the agglomerated particles.

A. Agglomerated Particles—Composition

In an embodiment, the agglomerated particles comprise binder and inorganic material. In an embodiment the inorganic material comprises rock and/or mineral fragments (i.e., fragments of (a) rock and/or (b) mineral). In an embodiment, the rock and/or mineral fragments comprise fines and/or larger particle sizes.

In one embodiment, the rock and/or mineral fragments are of such a particle size as to pass US Mesh 40. In other embodiments, the rock and/or mineral fragments are of such a particle size as to pass US Mesh 50, or US Mesh 60, or US Mesh 70, or US Mesh 100, or US Mesh 120, or US Mesh 140, or US Mesh 200, or US Mesh 230, or US Mesh 270, or US Mesh 325. Ranges based on any of the foregoing are also contemplated, e.g., the rock and/or mineral fragments may have particle sizes passing US Mesh 40 but retained by US Mesh 270.

Non-limiting examples of binders include sodium silicate, gypsum or other cementitious binders. Non-limiting examples of rock and/or mineral materials include igneous rocks such as basalt, andesite, and rhyolite, amphibolite produced from the metamorphism of the basalt parent such as metabasalt, or combinations thereof—e.g., basalt and metabasalt; basalt and andesite.

In an embodiment, the binder content of the agglomerated particles is at least about 1 wt %, at least about 2 wt %, at least about 3 wt %, at least about 5 wt %, or at least about 10 wt %.

In an embodiment, the binder content of the agglomerated particles is from about 1 wt % to about 10 wt %. In an embodiment, the binder content of the agglomerated particles is from about 1 wt % to about 8 wt %. In an embodiment, the binder content of the agglomerated particles is from about 1 wt % to about 6 wt %. In an embodiment, the binder content of the agglomerated particles is from about 1 wt % to about 3 wt %. In an embodiment, the binder content of the agglomerated particles is from about 1 wt % to about 2 wt %.

In an embodiment, the binder content of the agglomerated particles is from about 2 wt % to about 10 wt %. In an embodiment, the binder content of the agglomerated particles is from about 4 wt % to about 10 wt %. In an embodiment, the binder content of the agglomerated particles is from about 6 wt % to about 10 wt %. In an embodiment, the binder content of the agglomerated particles is from about 8 wt % to about 10 wt %.

In an embodiment, the binder content of the agglomerated particles is from about 2 wt % to about 8 wt %. In an embodiment, the binder content of the agglomerated particles is from about 3 wt % to about 6 wt %. In an embodiment, the binder content of the agglomerated particles is from about 2 wt % to about 3 wt %.

In an embodiment, the binder content of the agglomerated particles is about 3.5 wt %. In an embodiment, the binder content of the agglomerated particles is about 3 wt %. In an embodiment, the binder content of the agglomerated particles is about 2.5 wt %. In an embodiment, the binder content of the agglomerated particles is about 1 wt %.

In embodiments, the agglomerated particles comprise the binder content of any of the embodiments detailed herein with the rock and/or mineral fragments forming the remainder.

In an embodiment the agglomerated particles are coated. In an embodiment, the coating is semi-ceramic. In an embodiment, the semi-ceramic coating comprises silicate and clay. In an embodiment, the coating provides color to the agglomerated particles. In an embodiment, coated agglomerated particles are applied to the buttlap of the shingle.

In one embodiment, the agglomerated particles consist essentially of, or consist of, (a) the rock and/or mineral fragments and (b) the binder, or (a) the rock and/or mineral fragments, (b) the binder, and (c) the coating.

B. Agglomerated Particles—Particle Size Distribution

In an embodiment, the agglomerated particles have a particle size distribution. In an embodiment, the particle size distribution is monomodal, bimodal or multimodal. That is, the agglomerated particles may have one, two or multiple modal sizes.

In an embodiment, the particle size distribution of the agglomerated particles applied to the back surface of the shingle comprises at least about 10 wt % particles of US Mesh 50, at least about 20 wt % particles of US Mesh 50, at least about 30 wt % particles of US Mesh 50, or at least about 40 wt % particles of US Mesh 50. In an embodiment, the particle size distribution of the agglomerated particles applied to the back surface of the shingle comprises at least about 5 wt % particles of US Mesh 60, at least about 10 wt % particles of US Mesh 60, at least about 20 wt % particles of US Mesh 60, or at least about 30 wt % particles of US Mesh 60. In an embodiment, the particle size distribution of the agglomerated particles applied to the back surface of the shingle comprises at least about 5 wt % particles of US Mesh 100, at least about 10 wt % particles of US Mesh 100, at least about 20 wt % particles of US Mesh 100, or at least about 30 wt % particles of US Mesh 100.

In an embodiment, the particle size distribution of the agglomerated particles applied to the headlap of the shingle comprises at least about 20 wt % particles of US Mesh 16, at least about 30 wt % particles of US Mesh 16, at least about 40 wt % particles of US Mesh 16, or at least about 50 wt % particles of US Mesh 16. In an embodiment, the particle size distribution of the agglomerated particles applied to the headlap of the shingle comprises at least about 10 wt % particles of US Mesh 20, at least about 20 wt % particles of US Mesh 20, at least about 30 wt % particles of US Mesh 20, or at least about 40 wt % particles of US Mesh 20. In an embodiment, the particle size distribution of the agglomerated particles applied to the headlap of the shingle comprises at least about 5 wt % particles of US Mesh 30, at least about 10 wt % particles of US Mesh 30, at least about 20 wt % particles of US Mesh 30, or at least about 30 wt % particles of US Mesh 30.

In another embodiment, the particle size distribution of the agglomerated particles applied to the headlap of the shingle comprises at least about 1 wt % particles of US Mesh 20, at least about 2 wt % particles of US Mesh 20, at least about 5 wt % particles of US Mesh 20, at least about 10 wt % particles of US Mesh 20, at least about 20 wt % particles of US Mesh 20, or at least at least about 30 wt % particles of US Mesh 20. In an embodiment, the particle size distribution of the agglomerated particles applied to the headlap of the shingle comprises at least about 40 wt % particles of US Mesh 30, at least about 50 wt % particles of US Mesh 30, at least about 60 wt % particles of US Mesh 30, at least about 70 wt % particles of US Mesh 30, or at least about 80 wt % particles of US Mesh 30. In an embodiment, the particle size distribution of the agglomerated particles applied to the headlap of the shingle comprises at least about 2 wt % particles of US Mesh 40, at least about 4 wt % particles of US Mesh 40, at least about 10 wt % particles of US Mesh 40, at least about 20 wt % particles of US Mesh 40, at least about 30 wt % particles of US Mesh 40, or at least about 40 wt % particles of US Mesh 40.

C. Method of Making the Agglomerated Particles

1. Mixing

One embodiment of this invention pertains to a method of making agglomerated particles that are applied to the shingles. In an embodiment, rock and/or mineral fragments are combined with a liquid or dry binder in a pin mixer. In the pin mixer, pins or rods attached to a horizontal spinning shaft mix the components and produce agglomerated particles by the action of centrifugal force. In an embodiment, the agglomerated particles produced by the pin mixer are substantially spherical. In an embodiment, the agglomerated particles produced by the pin mixer may be dried and used directly. Agglomerated particles made by the pin mixer may be applied to the back surface or headlap of a shingle.

2. Pelletizing

In another embodiment, the agglomerated particles produced by the pin mixer are combined with further liquid binder in a disc or pan pelletizer. The agglomerated particle size is increased by the actions of tumble growth and centrifugal force. The agglomerated particle size may be controlled by varying the disc angle and speed of rotation, and by modulating the properties of the input particles and liquid binder. Once the desired agglomerated particle size is achieved the agglomerated particles may be dried. The disc or pan pelletizer increases the agglomerated particle size and produces agglomerated particles that may be applied to the buttlap of a shingle.

3. Drying

In an embodiment, the agglomerated particles are dried after leaving the pin mixer, or disc or pan pelletizer. In an embodiment, the agglomerated particles are dried in a fluid bed drying system. In the fluid bed drying system hot air flows through a perforated plate that both dries the agglomerated particles and moves the agglomerated particles through the apparatus. In an embodiment, the fluid bed drying system comprises multiple heating zones and a final cooling zone.

4. Carbon Dioxide Treatment

In another embodiment, the dried agglomerated particles (also referred to herein as “pellets”) are treated with CO₂ (i.e., carbon dioxide) gas. The dried agglomerated particles that are so treated may have decreased solubility as compared to untreated dried agglomerated particles.

Although there is no requirement that the drying that is carried out before the CO₂ treatment achieve any particular moisture content for the agglomerated particles, in some embodiments the agglomerated particles are dried to a moisture content of 0.4-5 wt % based on the total weight of the dried agglomerated particles. In some embodiments, the agglomerated particles are dried to a moisture content of 1-3 wt % based on the total weight of the dried agglomerated particles. In some embodiments, the agglomerated particles are dried to a moisture content of 1-2 wt % based on the total weight of the dried agglomerated particles. In some embodiments, the agglomerated particles are dried to a moisture content of 1-1.5 wt % based on the total weight of the dried agglomerated particles. Ranges with lower and upper values based on any of the foregoing are also contemplated, e.g., 0.4-1 wt %, or 0.4-1.5 wt %, or 0.4-2 wt %, or 0.4-3 wt %, or 1-5 wt %, or 2-3 wt %, etc. The moisture present in the dried agglomerated particles may facilitate the reaction of CO₂ with the dried agglomerated particles resulting in a decrease in the solubility of the dried agglomerated particles after CO₂ treatment. According to one embodiment, when the moisture content of the dried pellets is less than 0.5 wt % prior to CO₂ treatment, the reduction in solubility of the pellets after CO₂ treatment is decreased compared to dried pellets having a moisture content of 1-2 wt %. However, according to some embodiments, CO₂ treatment of pellets dried to less than 0.5 wt % still results in pellets having a lower solubility than pellets that have not been subjected to CO₂ treatment.

In some embodiments, in the CO₂ treatment the dried agglomerated particles are treated in a carbon-dioxide-rich atmosphere after drying. The CO₂ treatment may occur immediately after drying or may be conducted after a time interval. The drying and subsequent CO₂ treatment may be conducted on a continuous or batch basis.

A carbon-dioxide-rich atmosphere is one having a higher proportion by volume of carbon dioxide as compared to the atmosphere.

In one embodiment, the dried agglomerated particles are transferred to an enclosed treatment chamber where a supply of CO₂ raises the CO₂ levels in the chamber, e.g., so that the CO₂ levels in the chamber are greater than ambient CO₂ levels outside the chamber. In one embodiment, the supply of CO₂ raises the CO₂ levels in the chamber to 10-100 volume %. In another embodiment, the levels are 25-100 volume %. In another embodiment, the levels are 70-100 volume %. In another embodiment, the levels are 90-100 volume %. Ranges with lower and upper values based on any of the foregoing are also contemplated, e.g., 10-25 volume %, 10-70 volume %, 10-90 volume %, 25-70 volume %, 25-90 volume %, or 70-90 volume %, etc. In one embodiment, CO₂ levels in the chamber are measured using, as a CO₂ sensor, an IR sensor that is specifically calibrated to detect CO_(2,) and that can give readings in ppm or in volume %. In some embodiments, the raised CO₂ levels are maintained for the duration of the treatment, e.g., 10-120 minutes. In other embodiments, the duration is 30-120 minutes. In other embodiments, the duration of the treatment is 60-120 minutes. Ranges with lower and upper values based on any of the foregoing are also contemplated, e.g., 10-30 minutes, or 10-60 minutes, or 30-60 minutes, etc. The duration of treatment is not limited to 10-120 minutes. For example, in an embodiment where CO₂ levels are 10 volume %, the duration of treatment might extend for days. With further reference to the treatment chamber (also referred to as a reaction chamber), in one embodiment, the treatment chamber is a hopper with a lid on the top to mostly seal the hopper. The hopper includes a CO₂ inlet port near the bottom, a sensor port where the CO₂ gas sensor can be applied, a ball valve near the top, and a check valve leading inward. Operation is as follows. First, pelletized material (e.g., the dried agglomerated particles) is loaded into the chamber. Second, the lid to the chamber is shut. With the ball valve kept open, CO₂ is flowed into the chamber until the sensor reads the target CO₂ level. The ball valve is then shut and simultaneously the CO₂ flow is halted. As the CO₂ reacts with the pelletized material (e.g., it is thought that the CO₂ reacts with the binder (e.g., silicate)), there is the possibility that high negative pressure is achieved in the chamber. The check valve is to prevent damage to the chamber due to the high negative pressure that may be achieved, by allowing air to replace CO₂ that reacts. Once CO₂ levels drop below about 5% of the target levels, the ball valve is opened again, and CO₂ flow is continued. This process is repeated for the required duration of the treatment process.

In one embodiment, the supply of CO₂ may be a CO₂ gas cylinder. In another embodiment, the supply of CO₂ may include, for example, waste CO_(2.) One example of waste CO₂ is off-gas from a combustion process, or the like. In one embodiment, the combustion process may be a combustion reaction used to provide drying in the drying step discussed above.

It is thought that during the CO₂ treatment, CO₂ reacts with the binder in the pellets, and that such reaction reduces the solubility of the pellets.

The solubility of the pellets is determined using the following procedure:

(1) A sample of pellets is screened to 8×20 mesh.

(2) The screened sample is weighed to the nearest 0.01 g.

(3) The screened sample is immersed into boiling water using a wire mesh strainer for 5 minutes. As sample breaks down and disintegrates, the disintegrated particles fall through the mesh strainer and are removed from the sample.

(4) After 5 minutes of boiling, the strainer with the sample is washed with cold water to remove any remnant disintegrated particles.

(5) The sample is then placed into an oven to dry at 165 ° F.

(6) Once dried, the sample is weighed again.

(7) The solubility is calculated as a percentage of the mass of the pellets that disintegrated during the boiling step.

A pellet that has not been treated with CO₂ may exhibit solubilities ranging from 95-100%, whereas a CO₂ treated pellet exhibits a lower solubility. In some embodiments, a CO₂ treated pellet exhibits a solubility of 0-5%. In other embodiments, the solubility is 0-3%. In other embodiments, the solubility is 0-2%. Ranges with lower and upper values based on any of the foregoing are also contemplated, e.g., 2-5%, 3-5%, etc. Thus, in some embodiments, CO₂ treatment results in a large percentage reduction. For example, reduction from 100% solubility to 2% solubility represents a 98% reduction in solubility. As another example, reduction from 95% solubility to 3% solubility represents a 97% reduction in solubility, rounded to an integer value. As yet another example, reduction from 95% solubility to 5% solubility represents a 95% reduction in solubility, rounded to an integer value. Thus, in some embodiments, the percentage reduction in solubility is 95-100%, or 97-100%, or 98-100%, etc. Ranges with lower and upper values based on any aforementioned solubilities are also contemplated, e.g., 95-97%, or 95-98%, etc.

D. Method of Applying the Agglomerated Particles to a Roofing Shingle

In some embodiments, the invention relates to the method of applying the agglomerated particles to a shingle. In some embodiments, the method includes application of the agglomerated particles to at least one of the back surface, the buttlap or the headlap of the shingle. Manufacturing the shingle includes applying agglomerated particles to asphalt coated sheeting. The asphalt sheet is then pressed in a press roll unit, such that the agglomerated particles embed in the asphalt coating. The asphalt sheet is then cut to the desired shape on a machine line. In embodiments, the invention includes the method of making the agglomerated particles and applying the agglomerated particles to a shingle as detailed herein.

In one embodiment, the agglomerated particles are not sintered before being used. In other words, the agglomerated particles are, without being sintered, used to make a roofing material such as a shingle or roll roofing. As used herein “sintering” is the process of compacting and forming a solid mass of material by heat or pressure without melting it to the point of liquefaction.

E. Examples

Specific embodiments of the invention will now be demonstrated by reference to the following examples. It should be understood that these examples are disclosed by way of illustrating the invention and should not be taken in any way to limit the scope of the invention.

Examples

Example 1

An exemplary particle size distribution of the agglomerated particles applied to the back surface of a shingle is given in Table 1.

TABLE 1 US Mesh Tyler Mesh Wt % Retained 30 28 0-0 40 35 0-5 50 48 20-32 60 60 10-20 70 65  6-15 100 100 15-25 140 150  7-17 200 200  4-10 Pan Pan  2-11

Further exemplary particle size distributions of the agglomerated particles applied to the back surface of a shingle are given in Table 2.

TABLE 2 US Mesh Tyler Mesh Wt % Retained Range 30 28 0.0-0.0 40 35 3.1-4.8 50 48 19.9-21.6 60 60 13.3-13.8 70 65  9.5-10.8 100 100 19.5-21.6 140 150 13.2-14.4 200 200 8.8-9.0 Pan Pan 7.3-9.3

An exemplary particle size distribution of the agglomerated particles applied to the headlap of a shingle is given in Table 3.

TABLE 3 US Mesh Tyler Mesh Wt % Retained 8 8 0-0 12 10  4-10 16 14 30-45 20 20 25-35 30 28 14-24 40 35 2-9 Pan Pan 0-2

A further exemplary particle size distribution of the agglomerated particles applied to the headlap of a shingle is given in Table 4.

TABLE 4 US Mesh Tyler Mesh Wt % Retained 12 10 0-0 16 14 0-6 20 20  2-26 30 28 48-76 40 35  4-32 Pan Pan 0-6

The choice of particle size distribution selected for a shingle may be influenced by the balance of surface coverage, shingle weight, degree of flatness and impact resistance required.

By way of reference, below is a table, Table 5, showing the correspondence between US Mesh, Tyler Mesh, and the sieve opening size in inches and micrometers:

TABLE 5 ISO Standard Opening Standard Sieve Size inches (in) Mesh mm or μm as approximate US Tyler indicated equivalents mm Mesh Mesh 5.60 mm 0.2230 5.600 3.5 3.5 4.75 mm 0.1870 4.750 4 4 4.00 mm 0.1570 4.000 5 5 3.35 mm 0.1320 3.350 6 6 2.80 mm 0.1100 2.800 7 7 2.36 mm 0.0937 2.360 8 8 2.00 mm 0.0787 2.000 10 9 1.70 mm 0.0661 1.700 12 10 1.40 mm 0.0555 1.400 14 12 1.18 mm 0.0469 1.180 16 14 1.00 mm 0.0394 1.000 18 16 850 μm 0.0331 0.850 20 20 710 μm 0.0278 0.710 25 24 600 μm 0.0234 0.600 30 28 500 μm 0.0197 0.500 35 32 425 μm 0.0165 0.425 40 35 355 μm 0.0139 0.355 45 42 300 μm 0.0117 0.300 50 48 250 μm 0.0098 0.250 60 60 212 μm 0.0083 0.212 70 65 180 μm 0.0070 0.180 80 80 150 μm 0.0059 0.150 100 100 125 μm 0.0049 0.125 120 115 106 μm 0.0041 0.106 140 150 90 μm 0.0035 0.090 170 170 75 μm 0.0029 0.075 200 200 63 μm 0.0025 0.063 230 250 53 μm 0.0021 0.053 270 270 45 μm 0.0017 0.045 325 325 38 μm 0.0015 0.038 400 400 32 μm 0.0012 0.032 450 25 μm 0.0010 0.025 500 20 μm 0.0008 0.020 635

As discussed above, one example of rock and/or mineral is basalt; however, metabasalt (which is an amphibolite produced from the metamorphism of the basalt parent) may be used in addition to or instead of basalt. In other words, where the embodiments use the term basalt, they should be read as describing the use of basalt, metabasalt, or a combination of basalt and metabasalt.

Conclusion

While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art.

While various embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize many equivalents to the specific embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, embodiments may be practiced otherwise than as specifically described and claimed. Embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the scope of the present disclosure.

All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” Put another way, throughout the specification, the meaning of “a,” “an,” and “the” include plural references. Any ranges cited herein are inclusive.

The meaning of “in” includes “in” and “on.”

The terms “substantially”, “approximately,” and “about” used throughout this Specification and the claims generally mean plus or minus 10% of the value stated, e.g., about 100 would include 90 to 110. Thus, as used herein, the term “about X” means X plus or minus 10%. For example, “about 10 wt %” means 9 wt % to 11 wt %.

The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” may refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. Put another way as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning.

As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise.

As used herein, “wt %” refers to weight percent.

The terms “roofing shingle” and “shingle” are used interchangeably.

In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.

The claims should not be read as limited to the described order or elements unless stated to that effect. It should be understood that various changes in form and detail may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. All embodiments that come within the spirit and scope of the following claims and equivalents thereto are claimed. 

What is claimed is:
 1. A method comprising: obtaining (a) a plurality of fragments of at least one of a rock, a mineral, or a combination thereof and (b) a binder; mixing (a) the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof and (b) the binder to produce an agglomerated particle that is formed by agglomerating together the plurality of fragments and the binder; drying the agglomerated particle; and treating the agglomerated particle with carbon dioxide gas.
 2. The method of claim 1, wherein the treating the agglomerated particle with carbon dioxide gas comprises placing the agglomerated particle in a chamber having a greater than atmospheric level of carbon dioxide gas.
 3. The method of claim 2, wherein the greater than atmospheric level of carbon dioxide gas is from 25% to 100% by volume based on a total volume of the chamber.
 4. The method of claim 1, wherein the carbon dioxide gas comprises gas from a combustion process.
 5. The method of claim 1, wherein the treating takes place after the drying.
 6. The method of claim 5, wherein the treating the agglomerated particle with carbon dioxide gas comprises placing the agglomerated particle in a chamber having a greater than atmospheric level of carbon dioxide gas, wherein the greater than atmospheric level of carbon dioxide gas is from 25% to 100% by volume based on a total volume of the chamber, and wherein the treating the agglomerated particle with carbon dioxide gas extends for a time period of from 10 minutes to 120 minutes.
 7. The method of claim 6, wherein the greater than atmospheric level of carbon dioxide gas is from 70% to 100% by volume based on a total volume of the chamber.
 8. The method of claim 6, wherein the treating the agglomerated particle with carbon dioxide gas extends for a time period of from 30 minutes to 120 minutes.
 9. The method of claim 1, wherein the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size passing US Mesh
 40. 10. The method of claim 1, wherein the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size passing US Mesh 100 but retained by US Mesh 270, wherein the agglomerated particle is not sintered, wherein the agglomerated particle is configured to be applied to a sheet to form a roofing product, wherein the roofing product is a shingle or roll roofing, wherein the agglomerated particle is substantially spherical, wherein the at least one of a rock, a mineral, or a combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite, or a combination thereof, and wherein the binder is present in in the agglomerated particle in an amount of 1 wt % to 10 wt % with respect to a total weight of the agglomerated particle.
 11. The method of claim 10, wherein the binder is present in the agglomerated particle in an amount of 2 wt % to 8 wt %.
 12. The method of claim 11, wherein the binder is present in the agglomerated particle in an amount of 2 wt % to 6 wt %.
 13. The method of claim 1, wherein the binder comprises at least one of sodium silicate, gypsum, or a combination thereof
 14. The method of claim 1, wherein the binder comprises sodium silicate.
 15. The method of claim 1, further comprising coating the treated agglomerated particle with a coating comprising silicate and clay.
 16. The method of claim 1, further comprising: coating a sheet comprising a fiberglass mat with asphalt; and applying the treated agglomerated particle to the coated sheet.
 17. The method of claim 1, wherein the mixing comprises using a pin mixer, and wherein the method further comprises pelletizing the agglomerated particle before the drying.
 18. The method of claim 1, wherein the drying achieves a moisture content in the agglomerated particle of 0.4-5 wt % based on the total weight of the agglomerated particle.
 19. The method of claim 1, wherein the drying achieves a moisture content in the agglomerated particle of 1 to 3 wt % based on the total weight of the agglomerated particle.
 20. An agglomerated particle comprising: (a) a plurality of fragments of at least one of a rock, a mineral, or a combination thereof and (b) a binder, wherein the agglomerated particle is a carbon-dioxide-gas-treated agglomerated particle.
 21. The agglomerated particle of claim 20, wherein the carbon dioxide gas treatment comprises exposing the agglomerated particle to carbon dioxide gas other than atmospheric carbon dioxide gas.
 22. The agglomerated particle of claim 21, wherein the carbon dioxide gas treatment comprises exposing the agglomerated particle to an environment in which a level of carbon dioxide gas is from 25% to 100% by volume, wherein the agglomerated particle is configured to be applied to a sheet to form a roofing product, wherein the roofing product is a shingle or roll roofing, wherein the at least one of a rock, a mineral, or a combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite, or a combination thereof, wherein the plurality of fragments of the at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size passing US Mesh 40, wherein the agglomerated particle is substantially spherical, wherein the binder is present in the agglomerated particle in an amount of 2 wt % to 8 wt %, and wherein the binder is at least one of sodium silicate, gypsum, or a combination thereof.
 23. A roofing product comprising: a sheet to which is applied a plurality of particles, each being an agglomerated particle of claim
 20. 